DISTRIBUTE TO:
 Service Manager
 Warranty Administrator

Warranty Policy Bulletin

No.:
Date:
Page:

POL16-04
06/16/16
1 of 3

REVISED 8/30/19

SUBJECT: WARRANTY ENHANCEMENT PROGRAM (ZF3):
WARRANTY EXTENSION FOR STICKING EXHAUST GAS
RECIRCULATION (EGR) VALVE, FOR THE FOLLOWING
VEHICLES:
• CERTAIN 2010-2012 MY Prius
• CERTAIN 2012 MY Prius V
• CERTAIN 2010-2012 Prius Plug-In
Background
Toyota has received reports of a rough idle and/or rattle noise from the transaxle
at cold start due to a sticking Exhaust Gas Recirculation (EGR) Valve in some
vehicles. If this occurs, the vehicle may illuminate the check engine light and set
diagnostic trouble code (DTC) P0401.
Applicability
The EGR Valve is covered by Toyota’s New Vehicle Limited Warranty for 3 years
or 36,000 miles* (whichever occurs first). However, Toyota is announcing a
Warranty Enhancement Program to cover the repairs related to the EGR Valve
to address the condition described above in the covered vehicles.
Primary Coverage offers the Warranty Enhancement until March 31, 2017,
regardless of mileage.
After the Primary Coverage expires, the Secondary Coverage is applicable for
10 years from the date of first use or 150,000 miles, whichever occurs first.
* Note: For California-certified Prius and Prius Plug-in vehicles sold, registered,
and normally operated in Arizona (12MY only), California, Connecticut, Maine,
Maryland (beginning with 11MY), Massachusetts, New Jersey, New Mexico
(10MY-11MY only), New York, Oregon, Rhode Island, and Vermont, the
California Emissions Defect and Performance Warranty coverage is 15 years
from the date of first use, or 150,000 miles (whichever occurs first).
For California-certified Prius and Prius Plug-in vehicles sold, registered, and
normally operated in in Pennsylvania and Washington the California Emissions
Defect and Performance Warranty coverage is 7 years from the date of first use,
or 70,000 miles (whichever occurs first).

Toyota Warranty Policy Bulletin

POL16-04
06/16/16
REVISED 8/30/19
2 of 3

Applicability (Continued)
For California-certified Prius V vehicles sold, registered, and normally operated
in Arizona (12MY only), California, Connecticut, Maine, Maryland (beginning with
11MY), Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode Island,
Vermont and Washington the California Long-Term Emissions Warranty
coverage is 7 years from the date of first use, or 70,000 miles (whichever occurs
first).
Verify VIN applicability for this Warranty Enhancement by checking TIS before
completing any repairs.
Direct marketing of this Warranty Enhancement is strictly prohibited pursuant to
the Toyota Warranty Policy 5.21, “Warranty Solicitation.” Non-compliance of this
policy may result in a claim debit.
Please note that damage incurred from abuse, an accident and/or crash,
vandalism or other similar events is not covered by the New Vehicle
Limited Warranty or this Warranty Extension. All other terms and
conditions of the New Vehicle Limited Warranty apply.
Applicable VIN Ranges
Not all vehicles are covered by this warranty enhancement. Verify VIN
applicability for this warranty enhancement by checking TIS before completing
any repairs.
Claim Submission
Claim
Type

Model

Opcode

Prius
BHG10A
Repair
Program

Prius V
Prius PlugIn

•

BHG10B

Description
Replace the EGR
valve assembly
+
Modify the wire
harness
+
Reprogram the
engine ECU

OFP

Labor Time

2.8 hr./vehicle
25620-37120
2.7 hr./vehicle

The cost of Super Long-Life Coolant (SLLC) may be claimed, at a maximum of
$3.00 per vehicle, as Sublet Type “OF” under all opcodes listed above.

Please ensure this electronic bulletin is printed and distributed to those
designated as well as any other appropriate personnel.

Toyota Warranty Policy Bulletin

POL16-04
06/16/16
REVISED 8/30/19
3 of 3

Claim Submission (Continued)
Note: If the vehicle is still under the New Vehicle Limited Warranty, submit the
repair as a Regular warranty claim.
Replacement Parts
All parts replaced for this repair are subject to warranty parts recovery.
Part Number

Description

Quantity

Applicable
TSB

04004-58137*
25685-37010

Kit, EGR Valve
Gasket No.1, EGR Cooler

1
1

T-SB-0075-13

* The EGR Valve Kit includes the following parts:
Part Number
25620-37120

Description
Valve Assy, EGR

Quantity
1

25628-28010

Gasket, EGR Inlet

1

25634-37010

Gasket, EGR Pipe

1

25627-37010

Gasket, EGR Valve

1

Customer-Paid Repairs or Replacement of Components
If a customer has previously paid for the repair to address the condition
described above, please have them mail a copy of the repair order, proof-ofpayment, and proof-of-ownership to the following address for reimbursement
consideration:
Toyota Motor Sales, U.S.A., Inc.
Customer Experience Center, WC10
19001 South Western Avenue
Torrance, CA 90509
The customer name, address, and telephone number(s) should be included in
the request. The customer should allow 4-6 weeks for processing.

Please ensure this electronic bulletin is printed and distributed to those
designated as well as any other appropriate personnel.